Synthetic fireplace log

ABSTRACT

The present invention relates to a synthetic fireplace log and a process for making a synthetic fireplace log which is adapted to utilize wood derivative materials, such as wood chips, sawdust or virtually any wood-based product, such as paper and cardboard. The wood derivative materials are molded into a desired shape and held together with a non-petroleum based binder to form a synthetic fireplace log. In order to increase the flammability of the log, the synthetic fireplace log may optionally be sprayed or soaked with either a petroleum or non-petroleum-based flammability agent. Even though a petroleum-based flammability agent is used for soaking and/or spraying the synthetic log, the off-gassing is minimized since the petroleum-based spray is burned off relatively quickly. In other embodiments of the invention, a non-petroleum-based flammability agent is utilized. Suitable non-petroleum-based flammability agents include, for example, vegetable oil, corn oil, soybean oil, granola oil, and lard. These non-petroleum-based flammability agents produce no unpleasant odors. Moreover, the process for making the synthetic log is relatively simple and can be made from relatively inexpensive components, thus reducing the cost for making such synthetic logs.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. Provisional Patent Application No. 60/460,919 filed on Apr. 7, 2003.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a synthetic fireplace log and to a process for making a synthetic fireplace log and more particularly to a synthetic fireplace log which consists of wood derivative materials, such as wood chips, shredded paper, and the like molded together with a non-petroleum based binder and optionally coated and/or soaked with either a petroleum or non-petroleum-based flammability agent.

2. Description of the Prior Art

Various synthetic fireplace logs are known in the art. These synthetic fireplace logs are used in natural wood burning fireplaces. Examples of such synthetic fireplace logs are disclosed in U.S. Pat. Nos. 4,104,034; 4,654,049; 6,017,373 and 6,136,054. Such synthetic fireplace logs are known to include petroleum based binders and/or cores. Consequently, such known synthetic fireplace logs, when lit, produce a relatively unpleasant odor. For example, U.S. Pat. No. 4,104,034 discloses a synthetic fireplace log formed from compacted saw dust and a petroleum-based binder composition, which includes piccopale, manufactured from petroleum-based monomers, as well as paraffin. U.S. Pat. No. 4,654,049 discloses a synthetic fireplace log which includes a core formed from coal. An outer layer of compressed wood chips, held together with a binder, is formed over the core to form a synthetic log. U.S. Pat. No. 6,017,373 also discloses a synthetic log which includes compressed wood chips and/or sawdust in a petroleum-based binder. Finally U.S. Pat. No. 6,136,054 discloses a synthetic fireplace log formed from shredded cardboard and a petroleum-based binder. Unfortunately, such synthetic fireplace logs which utilize a petroleum-based binder or a petroleum-based core result in unpleasant off-gassing when lit. Thus, there is a need for a synthetic fireplace log which does not result in unpleasant off-gassing.

3. SUMMARY OF THE INVENTION

The present invention relates to a synthetic fireplace log and a process for making a synthetic fireplace log which is adapted to utilize wood derivative materials, such as wood chips, sawdust or virtually any wood-based product, such as paper and cardboard. The wood derivative materials are molded into a desired shape and held together with a non-petroleum based binder to form a synthetic fireplace log. In order to increase the flammability of the log, the synthetic fireplace log may optionally be sprayed or soaked with either a petroleum or non-petroleum-based flammability agent. Even though a petroleum-based flammability agent is used for soaking and/or spraying the synthetic log, the off-gassing is minimized since the petroleum-based spray is burned off relatively quickly. In other embodiments of the invention, a non-petroleum-based flammability agent is utilized. Suitable non-petroleum-based flammability agents include, for example, vegetable oil, corn oil, soybean oil, granola oil, and lard. These non-petroleum-based flammability agents produce no unpleasant odors. Moreover, the process for making the synthetic log is relatively simple and can be made from relatively inexpensive components, thus reducing the cost for making such synthetic logs.

4. DESCRIPTION OF THE DRAWING

These and other advantages of the present invention will be readily understood with reference to the following specification and attached drawing wherein:

FIG. 1 is a prospective view of a container for use in mixing the wood derivative product, with the binder material for use with the present invention.

FIG. 2 a is a perspective view of an exemplary square mold.

FIG. 2 b is a perspective view of an exemplary round mold.

FIG. 3 a is a perspective view of a synthetic fireplace log in accordance with the present invention after having been removed from the mold illustrated in FIG. 2 a.

FIG. 3 b is a perspective view of a synthetic fireplace log in accordance with the present invention after having been removed from the mold illustrated in FIG. 2 b.

FIG. 4 is a perspective view of a container for optionally soaking the synthetic fireplace logs illustrated in FIGS. 3 a and 3 b with a flammability agent.

FIGS. 5 a and 5 b illustrate exploded top and bottom views of the square mold illustrated in FIG. 2 a with the bottom tray removed.

FIGS. 6 a and 6 b are similar to FIGS. 5 a and 5 b but for the round mold illustrated in FIG. 2 b.

FIG. 7 is an exploded perspective view of a synthetic fireplace log and an exemplary mold.

DETAILED DESCRIPTION

The present invention relates to a synthetic fireplace log formed from various wood derivative materials formed in the shape of a fireplace log and held together with a non-petroleum based binder. In order to increase the flammability of the fireplace log, both petroleum and non-petroleum-based flammability agents can optionally be sprayed or used to soak the synthetic fireplace log. By utilizing a non-petroleum-based binder for binding the wood derivative materials, the amount of unpleasant off-gassing resulting from the petroleum flammability agent is minimized. In an alternative embodiment, non-petroleum-based flammability agents are utilized. In these embodiments unpleasant odors are basically eliminated.

The wood derivative materials include virtually any material derived from wood including wood chips, wood shavings, sawdust. The wood derivative materials may be derived from soft wood, such as pine, or hard woods, such as oak and cypress. The wood derivative materials may also include paper, such as newspaper, which may be shredded into quarter inch strips, for example.

In accordance with an important aspect of the invention, non-petroleum-based binders are used to hold the wood derivative materials together. Exemplary binders include flour, cornstarch, rice flour and potato flakes.

As mentioned above both, petroleum and non-petroleum-based flammability agents can be utilized. Petroleum-based flammability agents include various petroleum-based oils, paraffin, and petroleum-based resins, for example, as disclosed in U.S. Pat. No. 4,104,034. Non-petroleum-based flammability agents include flammability agents, such as vegetable oil, corn oil, soybean oil, granola oil and animal fat products, such as lard. Soaking and/or spraying the synthetic log in a petroleum-based flammability agent results in minimal petroleum-based off-gassing, thus minimizing unpleasant odors associated with burning the synthetic log. Alternatively, the natural flammability agents result in no unpleasant off-gassing.

Various types of molds can be used. These molds can be formed from virtually any material which can be used to shape a clay like material formed from the mixture of wood derivative materials, the binder and water. In one embodiment of the invention, it is contemplated that the mold can form a part of the synthetic log. In this embodiment, the mold is made of wood, or a wood derivative product, such as cardboard or wax-coated cardboard or other flammable material, which does not produce harmful or unpleasant off-gassing.

Other embodiments of the invention contemplate removable molds. These molds may be made of various materials, such as plastic or various other non-stick materials. As shown in FIGS. 2 a and 2 b, various geometric shape of the mold are contemplated. For example FIG. 2 a illustrates a generally rectangular mold, while FIG. 2 b illustrates a cylindrical mold. As shown, the exemplary molds illustrated in FIGS. 2 a and 2 b and identified with the reference numerals 20 and 22, respectively, may optionally be provided with a number of perforations, generally identified with the reference numeral 24. These perforations 24 may optionally be provided to expedite drying of the synthetic log within the mold.

EXAMPLE

In this embodiment, a generally rectangular mold 14½″×3½″×4″ is used for the synthetic fireplace log. A mixture of 8 parts water, 15 cups of wood derivative material and 1 cup of non-petroleum based binding material are placed in a container 26 (FIG. 1). The mixture is mixed and heated to a temperature, for example 150-190° Fahrenheit. The heating causes the mixture to turn into a clay-like material. The mixture is then placed in one of the molds 20, 22 and allowed to dry. The synthetic log is optionally removed from the mold and optionally drilled as illustrated to expedite drying of the log. After the synthetic log dries, either a petroleum or non-petroleum-based flammability agent may optionally either be sprayed, brushed or used to soak the synthetic log. The flammability agent may optionally be heated between 250° and 300° Fahrenheit before application. In lieu of drilling holes in the log to expedite drying, one of the panels 37 of the mold, for example the bottom panel, as illustrated in FIG. 7, may be provided with a number of spaced apart rods 36. Thus, once the clay-like mixture is placed into the mold and the bottom panel removed, the holes would already be formed in the log.

Obviously, many modifications and variations of the present invention are possible in light of the above teachings. Thus, it is to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described above. 

What is claimed and desired to be secured by a Letters Patent of the United States is:
 1. A synthetic fireplace log comprising: wood derivative materials; and non-petroleum based binder for binding said wood derivative materials.
 2. The synthetic fireplace log as recited in claim 1; wherein said wood derivative materials include wood chips.
 3. The synthetic fireplace log as recited in claim 1; wherein said wood derivative materials include saw dust.
 4. The synthetic fireplace log as recited in claim 1; wherein said wood derivative materials include paper.
 5. The synthetic fireplace log as recited in claim 1; wherein said wood derivative materials include cardboard.
 6. The synthetic fireplace log as recited in claim 1; further including a flammability agent.
 7. The synthetic fireplace log as recited in claim 6; wherein said flammability agent is petroleum based.
 8. The synthetic fireplace log as recited in claim 6; wherein said flammability agent is non-petroleum based.
 9. The synthetic fireplace log as recited in claim 1; wherein said non-petroleum based binder includes flour.
 10. The synthetic fireplace log as recited in claim 1; wherein said non-petroleum based binder includes cornstarch.
 11. The synthetic fireplace log as recited in claim 1; wherein said non-petroleum based binder includes rice flour.
 12. The synthetic fireplace log as recited in claim 1; wherein said non-petroleum based binder includes potato flour.
 13. The synthetic fireplace log as recited in claim 7; wherein said petroleum based flammability agent includes petroleum based oils.
 14. The synthetic fireplace log as recited in claim 7; wherein said petroleum based flammability agent includes paraffin.
 15. The synthetic fireplace log as recited in claim 7; wherein said petroleum based flammability agent includes petroleum based resins.
 16. The synthetic fireplace log as recited in claim 8; wherein said non-petroleum based flammability agent includes vegetable oil.
 17. The synthetic fireplace log as recited in claim 8; wherein said non-petroleum based flammability agent includes corn oil.
 18. The synthetic fireplace log as recited in claim 8; wherein said non-petroleum based flammability agent includes soybean oil.
 19. The synthetic fireplace log as recited in claim 8; wherein said non-petroleum based flammability agent includes granola oil.
 20. The synthetic fireplace log as recited in claim 8; wherein said non-petroleum based flammability agent includes animal fat products. 